Oracle Flow Manufacturing

Oracle Flow Manufacturing

Sid Perera Principal Consultant

Oracle Manufacturing Solution Integrated Intelligence

Cost Analysis

Planning

Flow CTO ETO MTS

• Planned Orders • Schedule Changes • Component Substitutes • Resources Substitutes

Process Sample

Product Lifecycle Mgmt

Real-Time WIP Visibility

Mixed Mode Discrete

Productivity

Model Shop Floor Lot-Based

Analyze

Adjust

Warehousing / Transportatio n

Contract Mfgrs Suppliers

Asset Maintenance

Quality Management Service

Lot / Serial Genealogy Tracking

• Demand Schedules • Sequencing • Configured Order

• • • • • •

MES APIs, Direct Access

Production Status Material Availability Mfg Capacity Schedules/Changes Ship Notices Invoices/Payments

Partner Collaboration Customer

Enterprise Shop Floor

Contract Mfgrs

Suppliers

What is Flow Manufacturing? ● ● ● ●

● ● ●

More than a module - its a “new way of life” Dedicated assembly lines supporting product families Mixed model production - lot size of one Balanced line ensures smooth flow and optimum resource utilization Demand driven line and cell schedules Pull manufacturing Point-of-use kanban replenishment

Oracle Flow Manufacturing Solution Enables you to:

1. Plan for Customer Demand (Configured Products) 2. Design for Balanced Operations 3. Schedule and Sequence for Efficiency 4. Communicate and Complete Production 5. Plan for and Execute Kanban Management



Plan for Customer Demand Techniques ● used Complete Integration with Oracle

Planning Products, Planning Workbench ● Product Family Definition and Planning ▪

Model Definition ▪ Option Class with Planning Percent ▪ Optional Items with Planning Percent

● Two-level Master Scheduling

Production Planning ● Forecasts at family level ● Explode family forecasts to members ● OR - plan based on unconsumed family forecast ● Consume family forecast with member demand ● Check ATP by product family or individual item Product Family Laptops

Forecast & Consume Sales Orders

Envoy Sentinel 20%

Envoy Presidential 30%

Envoy Multimedia 50%



Design for Balanced Operations

1 2 3 4 5 6

Install Red Capacitor

Int\Ext

Qty

Dynamic / Static

Labor

Task

Machine

Seq.

Value Add?

Setup

Machine Labor (sec)

Sequence of Events Document

0

Move to Chip Dept

600

Install Yellow Chip Move to Insp/Test Inspect - Test Move to FGI Warehouse

Machine Time

1

Move

Description

To Chip Dept

Ensure snap to board

To Inspection

Right of Red Cap.

600

0

1

600

600

0

1

600

600

To FGI Warehouse To Shipping

= 1800 Sec or 30 Min.

Labor Time = 1803 Sec or 30.05 Min. Elapsed Time = 1803 Sec or 30.05 Min. Work Content

=

Quality Info.

3 Sec!!!

Compare Order to Product


Example Processes, Sequence of Events, & Operations PROCESSES >

SEQUENCE OF EVENTS >

LINE OPERATIONS >

Welding

Assembly

mount surface s

weld edges

Op 10

Op 20

bolt moto r

seal end s

attach legs

Op 30 Production line

Painting

clean surfac e

Op 40

paint polish surfac surfac e e

Op 50


Other Objectives Flat BOM

Complex Bill - high maintenance Concurrent Process Engineering Visual Network Routings Design without considering the factory process

Design for Balanced Operations How Oracle Supports Them

▪ Graphical Line Designer ▪ Network Routings ● Sequence of work events ● Network of operations ▪ Alternate Paths ▪ Feeder Lines ▪ Drag and Drop

Example


Graphical Line Designer Primary, Alternates, Rework, Subassembly Feeder, Etc.


Graphical Line Designer Sequence of Events


How do I balance the line? How Oracle Supports It

● Mixed Model Map Workbench ▪ Analyze Different Scenarios ▪ New Product Introduction ▪ Changes in Demand ▪ Process Improvement ▪ Bottleneck Resolution


How do I balance the line? Example Processes, Sequence of Events, & Operations PROCESSES >

SEQUENCE OF EVENTS >

LINE OPERATIONS >

Welding

Assembly

mount surface s

weld edges

Op 10

Op 20

bolt moto r

seal end s

attach legs

Op 30 Production line

Painting

clean surfac e

Op 40

paint polish surfac surfac e e

Op 50

Mixed Model Map

Mixed Model Map


How do I balance the line? Line Balancing Mixed Model Map Workbench


How do I balance the line? Mixed Model Map Workbench Bottleneck resolution

Mixed Model Calculations ● Line Takt Time = ((Mts/Day)x No of Dem Days))/Total Demand ● Machines Needed= MC Wtd Time/Opn Takt Time ● MC Assigned=Tot No of MC (In the dept) ● Labor Needed= Lbr Wtd Time/Opn Takt Time ● Labor Assigned=Tot Av (In the dept)



Line Scheduling

Line Scheduling Objectives ●

●

●

●

Schedule production based on customer orders (or planned orders) Sequence production based on model mix to maximize line utilization Smooth demand fluctuations using demand fences Review material and resource availability for product family schedule

Scheduling Algorithms ● No Level Loading – –

Scheduled by “Scheduling Criteria” Scheduled until capacity is reached

● Level Daily Rate –

Total demand is spread evenly across scheduling horizon

● Mixed Model – –

Same as Lvl Daily Rate Follows a production rule pattern for mix

Sequencing Criteria Sales Orders ● Order Entry Date ● Order Priority ● Order Promise Date ● Order Request Date ● Order Scheduled Date

Planned Orders Planned Order Due Date

Line Scheduling Line Scheduling Workbench ● ● ● ● ●

Sequence based on user-defined priorities Schedule to line rates Balance production lines Schedule mixed-model production Execute directly from sales order demand

Line Scheduling Sales Order Demand

Product A

Product B

Product B

Product A

Product B

Product A

Product A

SO 1

SO 2

SO 3

SO 4

SO 5

1-JUN

2-JUN

3-JUN

4-JUN

5-JUN

Priority 2

Priority 1 Priority 3 Priority 2

Priority 1

Line Scheduling Algorithm = No Level Load, Criteria = Order Priority, Date Line Capacity SO 2

SO 1

SO 4

SO 5

SO 1

SO 4

SO 3

1-JUN

2-JUN

3-JUN

4-JUN

●

Schedule only 4 days of production

SO 3

Unscheduled

Line Scheduling Algorithm = Level Daily Rate (Spread Demand Evenly) Line Capacity Product B

Product B

Product B

Product B

Product A

Product A

Product A

Product A

1-JUN

2-JUN

3-JUN

4-JUN

●

Unscheduled

Same criteria options to sequence orders

Line Scheduling Algorithm = Mixed Model Scheduling (Production Rule Pattern) Line Capacity

1-JUN

2-JUN

3-JUN

4-JUN

Unscheduled

Schedule and Sequence for Efficiency Techniques Used

● ● ● ● ● ● ●

Sequence Based on User-Defined Priorities Execute Directly From Sales Order Demand Schedule Mixed-Model Production Balance Production Lines Feeder Line Synchronization Supplier Synchronization What Ifs and Simulations

User Defined Sequencing Rules Selected data attributes applied to constraints

36

Constraint Sequencing for Efficiency

37

Schedule Sales Order or Planned Order Demand Line Scheduling Work Bench

38

Schedule Sales Order Demand LSWB –Demand dates and Production dates

39

Mixed Model Schedule Summary LSWB –Balanced Mixed Model Production

40

Mixed Model Schedule Summary LSWB –Balanced Mixed Model Production

41

Mixed Model Schedule Summary LSWB –Detailed schedules with Sales Order reference (Different Item)

42

Mixed Model Schedule Summary Capacity Check

43

Mixed Model Schedule Summary Capacity Check

44



Plan for and Execute Kanban Management Techniques ● used Define Pull Sequences

● Calculate #of Cards / Kanban Size ● Kanban Requirements Simulation ● Generate Non-Replenishable Kanbans ● Automate Transactions - Generate Requisitions

Plan for and Execute Kanban Management Pull Sequences Op 10

loc 1

item A

inter-org i1

Op 20 raw in loc process 2 item B

Op 30 Production line raw in

supplier s1

loc process 3 item A

supplier s2

Op 40 loc 4 item C

line l1

Op 50 loc 5 item D intra-org r1

item D supplier s3

Replenishment Chain

Replenishment Chain

Replenishment Chain View by: Supplier, Buyer, Location

Plan for and Execute Kanban Management Kanban Execution ● Signals Replenish Internal Kanbans – –

Stores Move (Intra-Org) Production

● Replenish External Kanbans –

Supplier Kanbans ● Aggregate Kanban Signals

–

Move Order (Inter-Org)

● Non-replenishable Kanbans

Supplier Kanban Execution Purchase to Build – Component demand and Production Sequence communicated to suppliers.

52



Communicate and Complete Production Techniques Used ● Flow Workstation ▪ ▪

Communicate Schedule Convey Work Instructions (OMS)

● Work Orderless Completion ▪ ▪ ▪ ▪ ▪

Extremely Lightweight Entity No Pre-exploded Bills and Routings Substitutions and Changes Management of Engineering Changes Serial / Lot Control, FG and Components

● Scrap Reporting ● Quality Collection Integration

Flow Workstation Paperless Communication of Production Schedule - work instructions, OMS, components, resources




Attachments

Work Order Less Completion

Work Order Less Completion

No Pre-exploded Bills and Routings, Management of Engineering Changes, Substitutions and Changes, Serial / Lot Control, FG and Components, Scrap, Quality Integration, Mobile Support

Summary

Oracle Flow Manufacturing ● Complete Flow Infrastructure –

Flow and ERP Data Model Integration

–

Demand Management

–

Line Design and Balancing

–

Line Scheduling

–

Production Execution

–

Kanban Planning and Execution

Know More. Do More. Spend Less.

Oracle Flow Manufacturing

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